ATVingPA

Front Passenger Drive Shaft

Posted By: Ridgekid

Front Passenger Drive Shaft - 02/22/13 02:56 PM

OK? How does this happen? The Drive shaft on passenger side has popped out the front Diff.

The A arm is not broken. Did I loose the CV joint?

Posted By: Gary

Re: Front Passenger Drive Shaft - 02/22/13 03:48 PM

I can't see all that clear but the clip looks like it's still there. Is your boot torn? If not just pop the shaft back on and see if it stays. If not then You'll have to see where the damage is. Axel or diff.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/22/13 04:06 PM

Looks like the boot is torn (effident from grease). Diff seems to still be bolted in place. Other shaft still looks good. I'll take it apart later today for a full inspection.

I am removing and replacing shaft assembly. ($180)

Do you know if they make rebuild kits to rebuild. IS that possible? I was thinking about rebuilding and saving for a spare.

Still can't figure out how it could pop out like that.
Posted By: Gary

Re: Front Passenger Drive Shaft - 02/22/13 04:17 PM

Normally they pop out when your machine is lifted and your doing extreme angles. Possible your cv binded up and pop. I've never been a big fan of rebuilding cv's.
Posted By: Gary

Re: Front Passenger Drive Shaft - 02/22/13 04:21 PM

Also check out superatv. You can get there ADR brand complete axel/cv for $119.95. Heck the rebuild for the cv is 79.99
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/22/13 04:26 PM

Rebuild prices sound like a waste of time then. Ill just hide it from my son for awhile as he is a scrapper. Lol.

Oh, and I hope that's all it is. I had it up in the air to check brakes a few weeks ago. Maybe it happened then???
Posted By: Rrudzi

Re: Front Passenger Drive Shaft - 02/22/13 11:39 PM

The clip is still there just not in the groove. From the pic it looks as tho the clip was never installed correctly on the shaft in the groove and that's why it came out of the diff. Look at the splines on the shaft that are clean the axle was only in the diff that far. I don't think that was far enough.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/23/13 01:03 AM

I got it off. I think both of you are.correct. It either popped off when I was on the jack last time or it never was inserted correctly. When it popped off it damaged the cv boot. Anyone know how to replace it?

No real damage to the diff. End of the shaft marred the outside of the diff casing.

I got the shaft off without removing A arm or steering linkage. Not sure I can put it back together without removing those.

New shaft assembly arrives Wednesday.
Posted By: Gary

Re: Front Passenger Drive Shaft - 02/23/13 01:20 AM

No you won't be able to put back on without removing your upper and lower ball joints.
If you want let me know and I'll PM you the exact procedure.
Posted By: Myleslong

Re: Front Passenger Drive Shaft - 02/23/13 01:49 AM

You have to remove the knuckle, but you don't need to remove the A-arms. The axle just pops right back into the diff. Look inside the diff and check your splines on the end of your axle. I never rebuilt one but I bet the hardest part is getting those straps tight on the outside of the boot and the worse part would probably be packing the boot with grease if you don't like getting greasy. LOL!! I put on rubber gloves for a lot of the grease jobs we do at work. Had I not destroyed both axles I replaced on my Cat I would have rebuilt them. I think mine were like $250 a piece. When you put it all together check your torque settings. I tore my old axles apart just to see what they looked like under the boots and how they go together. It looked like it would be easy to rebuild one, but again I haven't had to do it yet.LOL!! Give me time and I'm sure I'll have to eventually. BAH HA HA HA HA!!!
Posted By: Gary

Re: Front Passenger Drive Shaft - 02/23/13 01:55 AM

Myles I Pm'd him the full directions he should be good to go. And for putting those boots on Your right.. I hate doing those so bad I won't even try anymore. And he will have to loosen and remove the upper ball joint to get enough room to get the shaft back into the carrier bearing without damageing it. And always remember to use anti seize on the splines. Helps the next time YOUR removing... LOL
Posted By: Myleslong

Re: Front Passenger Drive Shaft - 02/23/13 02:10 AM

Now I know how I pulled a axle apart when removing it from the diff and had to use a blind bearing puller to get the other half of the shaft out of the diff LOL!! I need to start using anti seize. LOL!! Gary I'm getting some.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/23/13 01:35 PM

Gary thanks for info. New axle delivery Tuesday.

Axle removed only needs a boot. Going to check around and see what it will cost to repair.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/23/13 05:52 PM

FYI-dealer wants $78 to replace the boot.

I found the "kit" on line for $20. Includes Grease, clamps and boot.

Just need pliers for the clamp. Advance auto sells them.

Instructions on how to replace boot? In Maintenance manual.

I'll let you know if I'm successful or not.
Posted By: Gary

Re: Front Passenger Drive Shaft - 02/23/13 08:24 PM

Good deal. Your ready to go
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/26/13 09:58 PM

So the new axle is on. Pretty straight forward following directions.

Take it for test drive and it looks like it wants to pop off again. If you look in the original picture you see three colors on the spline. Doesn't it look like its been riding with some of the splines exposed?

Anyway, I'm at a loss. Do I need to take it apart again and get it to catch again???
Posted By: monkeywrench

Re: Front Passenger Drive Shaft - 02/26/13 10:17 PM

From what I see in the picture, the snap ring isn't in place and the axle wasn't in all the way. Are you sure there isn't a bent A-arm or the frame? Have you hit anything HARD lately?
Are the wheel bearings good? Something isn't letting that axle go in the whole way.
Posted By: Gary

Re: Front Passenger Drive Shaft - 02/26/13 10:57 PM

What axel did you buy and did it come with a new spring ring? When you installed did it snap in place?
I know on rzr's there have been some issues with after market spring rings not holding the axel in.
As Monkeywrench asked did you do any damage lately that could have caused another problem.
You can try to re-seat it as is but you'll prob. have to start over.
Posted By: Jim

Re: Front Passenger Drive Shaft - 02/26/13 11:03 PM

this might be of help also


http://www.prcforum.com/viewtopic.php?t=45786&sid=41f9ee8acf4d3cd044861a1a70629f51
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/27/13 12:05 AM

Monkey-that's the old axle and the way I found it. Bearings are good and no bent a arm.

Gary- aftermarket axle with new circllip.

Jim. I'm actually a member there. Did not see that post. And I think that's exactly what's happening with mine!

I did not hear a snap ( as the circllip grabbed). But I yanked it and it did not pop out. It was clean and I lubed with anti seize. Will try one more time and then do what the last poster did. Move the diff 1/16" towards right or passenger side.

Sounds like polaris had a template problem with the machine that drills holes!!!!
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/27/13 01:03 AM

Gary. Got a complete axle here:

http://stores.channeladvisor.com/atv-parts-connection/?sck=4243609
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/28/13 01:54 AM

Does this look like it popped out recently? I think its been like that since day one based on the erosion of the exposed splines.


Posted By: Myleslong

Re: Front Passenger Drive Shaft - 02/28/13 01:57 AM

I think I've pulled my axles out and they looked like that. I'll have to see if I have any pics. Ok I found some pics of my Cats axles, one is new and one is old, And I think I'm wrong. the old axles splines look almost as nice as the new ones. Here's the pics.

Posted By: Myleslong

Re: Front Passenger Drive Shaft - 02/28/13 02:09 AM

Here's a pic of one of mine on the cRaZR4 just hanging there. It didn't pop out with out some good hard yanks. When they pop in there they don't usually just fall out. I've pulled 4 or 5 and 2 I ended up cutting the bands on the boot cause I yanked so hard I pulled the axle apart and had to use a blind bearing puller from harbor freight to get the rest out of the diff. All I would say is slam it in there and see if it pops in there. If you yank on it and it don't just slide out you got it seated.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 02/28/13 02:45 AM

Thanks miyles.!! Your right - both shafts looks like new on the diff side.

I'm going to pick up a new circllip and if necessary move the diff over 1/16". One way or another I'm going to make that shaft stick!!!
Posted By: Rrudzi

Re: Front Passenger Drive Shaft - 02/28/13 03:01 AM

when reinstalling an axle shaft I make sure the splines and the clip have a good coating of antiseize on them and the clip opening is on the bottom and a love tap from my brass hammer.
Posted By: Gary

Re: Front Passenger Drive Shaft - 02/28/13 04:30 PM

Originally Posted By: Ridgekid
Thanks miyles.!! Your right - both shafts looks like new on the diff side.

I'm going to pick up a new circllip and if necessary move the diff over 1/16". One way or another I'm going to make that shaft stick!!!


RK
New c clips good idea.
Tap with plastic hammer to get seated good idea.
Move front diff. BAD IDEA
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 03/01/13 10:22 PM

Could not find new circlips. FYI- bike town in Austintown, Ohio has nothing as far as parts go for polaris goes. Nor sure why they sell them........ Thier main line seems to be Harley's.

Will try re-install Saturday. Without moving diff. If it doesn't work Gary is coming over to show me what I'm doing wrong.

Right Gary???
Posted By: Gary

Re: Front Passenger Drive Shaft - 03/01/13 11:31 PM

You got it bud
Posted By: Jim

Re: Front Passenger Drive Shaft - 03/02/13 03:12 AM

Check with snows polaris for those clips
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 03/02/13 03:56 AM

If I don't get it tomorrow, ill look for the parts during my next business trip.

Snows is too far away.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 03/02/13 04:11 PM

Oh Well....it didn't work!

My son came over and I gave him a detail report of what was happening. We took it all apart and push the shaft back in. Giving it a tap with a hammer he swore he heard the clip "snap".

We put the strut back on the A arm, connected the steering linkage and commenced putting the rotor back on. While tightening the locknut for the rotor we noticed the shaft coming out of the Diff.

We repeated the same procedure the second time with the exception that we lifted the strut up with a floor jack getting the shaft as straight as possible. We finished the assembly, including the tire and lowered back to the ground. Walah-it stayed together!!

Well, wishful thinking anyway. We took it for a ride (About a mile) and checked it when we returned. Although it didn't fall out, and it was still splined, it was not being held by the circlip.

As you recall my previous statement that the splines on the old shaft seemed to be exposed for an extended period of time? I think thats the case again.

I'm going to pick up new circlips on my next business trip, but I really don't think it's a circlip problem.

Gary-I'll call you when I get back to town.

Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 04/01/13 01:39 PM

Thought it was time for an update. No it's still not working the way it was intended, but it's working as it was before I discovered it. Shaft will not stay clipped, but won't come off unless I lift the front end.

Original Shaft- I was able to get the boot off and just waiting for new circlip to put new boot on.

Replacement Shaft- I'll need to do the same thing to this one. As I was using a wood handle to push the shaft on (by hand) it tore a hole in the boot.

So Gary....when we meeting at Tri County??
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 04/29/13 08:17 PM

GARY- The saga continues. As you know we were able to snap in the passenger shaft during your visit to tri county. Today I heard an unusual noise again. This time the CV joint snapped.

Luckily that piece that was in the diff (held in by circlip) came off with slight pressure.

Going to rebuild the original shaft and put it on.....
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 04/30/13 12:38 AM

I now know how to install a replacement boot!! Hardest part was the clamps until I learned how to use the tool correctly, then it was easy..

I'm back to not being able to snap the shaft back in the diff. But I think I know the secret. Put it on the trailer, strap it down and have Gary looking over your shoulder and telling you " there ... It snapped in".
,
happydance
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 05/01/13 11:30 AM

Great minds think alone.......

I not only figured why I can't get the shaft to snap into the diff, but why the CV joint came apart. The shaft is either too short or the diff is in the wrong place!

When I disconnect the hub I can push the shaft in the diff with no problem. You can even hear it snap in. As soon as I tighten the hub I pull it out of the diff.

I put a 1/8" thick washer on the back side of the wheel hub (Yeah I had one that fit over the shaft) I now have some free play (like I do on the Drivers side)

I'm going to take the old shaft apart and use it as spare parts in case I ever break another (front) shaft.

Thanks for listening........
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 06/16/13 05:22 PM

Good news...the repair last 6 weeks. Bad news. It broke again......

So no one knows of a permanent fix??? Longer shaft?? Move the front diff???

For now ill be three wheel drive as I have pulled the shaft but left the hubs on.
Posted By: Gary

Re: Front Passenger Drive Shaft - 06/17/13 01:41 AM

Dang, Your not having any luck with that at all. I think it maybe time to get some after market axels and cv's. Superatv for a set of Rhino axels complete with the hd cv's.
Posted By: TUT

Re: Front Passenger Drive Shaft - 06/17/13 02:46 AM

Because I'm a cheap S.O.B. check-out cheapparts.com
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 06/17/13 02:51 AM

Will they be any longer? My calculation is up to 1/4" short on Oem shaft. At least for my Ranger 400 anyway.
Posted By: Gary

Re: Front Passenger Drive Shaft - 06/17/13 11:30 AM

Originally Posted By: Ridgekid
Will they be any longer? My calculation is up to 1/4" short on Oem shaft. At least for my Ranger 400 anyway.


Yes they are. And the cv's can take alot more articulation than stock.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 06/17/13 06:15 PM

Thanks Gary!

I've asked fixmytoys.com to talk to their technicians and to see if they can get a response from Polaris on the same subject. I'll let you know if I hear anything.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 06/24/13 04:59 PM

no response from fixmytoys. I went with your suggestion. They claim the Rhinos have plunging CV's on both sides vs one side with OEM.

We'll see!
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 06/25/13 09:14 PM

After all that trouble to get the circlip to stick into the front diff I had a hard time getting the hub out. I read the precautions of prying on the aluminum housing and heeded that caution.

I ended up tapping the hub on further, which I think compresses the circlip. Then a quick jerk outward and it popped off.

Tomorrow I get the new axle.
Posted By: Ridgekid

Re: Front Passenger Drive Shaft - 06/27/13 10:53 AM

ok. New axle is on (Rhino) definitely beefier than OEM. New Concern is boots rubbing the inside of strut bore.

It looks like it might rub on inside of splash guard too.
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